Battery cooling method and system

ABSTRACT

An apparatus may store at least one object including at least one top end and at least one bottom end. The apparatus may include a container configured to store the at least one object and a pouch containing a liquid. The pouch may be configured to substantially cover the at least one top end of the at least one object when stored inside the container. The pouch may be configured to contact the at least one top end of the at least one object and to open when contacted by contents expelled from the at least one object due to thermal runaway.

PRIORITY

This application claims the benefit of priority from U.S. ProvisionalApplication No. 61/506,401, filed Jul. 7, 2011, which is hereinincorporated by reference in its entirety.

FIELD

The present disclosure relates generally to a cooling method and system,and more particularly, to a battery cooling method and system.

BACKGROUND

Batteries, such as lithium or lithium-ion batteries, may experiencethermal runaway under certain conditions, e.g., when defective, damaged,overcharged, overheated, etc. When a battery experiences thermalrunaway, the battery may increase in temperature until the battery ventshot, pressurized gases (e.g., at approximately 450 to 500 degreesFahrenheit). While venting gas, the battery may continue to increase intemperature (e.g., up to approximately 1,000 to 1,050 degreesFahrenheit). Jets of flaming materials (e.g., flaming liquidelectrolyte) and/or smoke may also be produced and vented from thebattery. Sufficient heat, gases, and/or flames may be produced to leadto the combustion and destruction of materials in close proximity to thebattery, such as the package surrounding the battery.

Multiple batteries are often stored and packaged together in a singlepackage for transport and/or other applications. However, when onebattery in the package experiences thermal runaway, the high heat,gases, and/or flames produced by the battery may contact and/or heatadjacent batteries in the same package, causing the adjacent batteriesto overheat and experience thermal runaway as well. A chain reaction mayoccur as each battery experiencing thermal runaway may cause adjacentbatteries to also experience thermal runaway. Thus, if a batteryundergoing thermal runaway is surrounded by one or more additionalbatteries in a package, then a single thermal runaway event may lead tothe thermal runaway of multiple batteries which, in turn, may lead tomore extensive collateral damage. For example, the package containingthe batteries may be destroyed, and when multiple batteries areundergoing thermal runaway, temperatures up to approximately 2,500degrees Fahrenheit may be reached. Thus, thermal runaway is a concernsince a single incident in one battery may lead to significant propertydamage and, in some circumstances, bodily harm or loss of life.

The disclosed method and system is directed to overcoming one or more ofthe problems set forth above.

SUMMARY

In accordance with one example, an apparatus for storing at least oneobject including at least one top end and at least one bottom endincludes a container configured to store the at least one object. Theapparatus also includes a pouch containing a liquid and configured tosubstantially cover the at least one top end of the at least one objectwhen stored inside the container. The pouch is configured to contact theat least one top end of the at least one object and to open whencontacted by contents expelled from the at least one object due tothermal runaway.

In accordance with another example, a method of storing at least oneobject having at least one top end and at least one bottom end includesplacing the at least one object into a container. The method alsoincludes placing a pouch containing a liquid on the at least one top endof the at least one object such that the pouch substantially covers theat least one top end of the at least one object. The pouch includes alayer configured to contact the at least one top end of the at least oneobject and formed from a material having a melting point of less thanapproximately 400 degrees Fahrenheit.

In accordance with a further example, a method of storing a plurality ofobjects having top ends and bottom ends includes placing the pluralityof objects into a container. The plurality of objects are parallel suchthat the top ends of the plurality of objects are aligned and the bottomends of the plurality of objects contact a surface of the container. Themethod also includes placing a pouch containing a liquid on the top endsof the plurality of objects such that the pouch substantially covers theplurality of objects. The pouch is configured to contact the top ends ofthe plurality of objects and to open when contacted by contents expelledfrom at least one of the plurality of objects due to thermal runaway.

In accordance with yet another example, a container defining a cavityand configured to transport objects includes a fluid and at least onesealed enclosure. The sealed enclosure is configured to (i) contain thefluid, (ii) substantially cover a top end of at least one object in thecontainer, (iii) make contact with the top end of the at least oneobject, and (iv) release the fluid when a content from the at least oneobject is expelled.

It is to be understood that both the foregoing general description andthe following detailed description contains examples only and is notrestrictive of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the assembly of a container including apouch and multiple batteries, according to an example embodiment;

FIG. 2 is a cross-sectional view of the container of FIG. 1;

FIG. 3 is a cross-sectional view of the container of FIG. 1 with aventing battery;

FIG. 4 is a cross-sectional view of the container of FIG. 1 in which thepouch is opened;

FIG. 5 is a cross-sectional view of a pouch formed with sheet materialencapsulating air pockets, according to an example embodiment;

FIG. 6 is a cross-sectional view of a container including a waterprooflayer, according to an example embodiment;

FIG. 7 is a perspective view of a container, according to anotherexample embodiment, with a closed lid;

FIG. 8 is a perspective view of the container of FIG. 7 with an openedlid, and including a pouch and multiple batteries; and

FIG. 9 is a perspective view of the container of FIG. 7 with an openedlid and the pouch removed.

DETAILED DESCRIPTION

Reference will now be made in detail to example embodiments that areillustrated in the accompanying drawings. Wherever possible, the samereference numbers will be used throughout the drawings to refer to thesame or like parts.

FIGS. 1-4 illustrate an example container 10 for storing one or morebatteries 20, e.g., during transport or for other applications. Thecontainer 10 may include at least one side wall 12 and a bottom surface14 that define a space in which to store the batteries 20. In theexample embodiment shown in FIG. 1, the container 10 is a rectangularprism including four side walls 12, but the number of side walls 12 mayvary depending on the shape of the container 10. Further, the container10 may have at least a partially opened top (e.g., no lid) or mayinclude a closeable lid.

The container 10 may be formed from various types of materials. In theexample embodiment shown in FIGS. 14, the container 10 is formed fromcorrugated cardboard. Alternatively, the container 10 may be formed fromother materials typically used as packaging materials, such as othertypes of cardboard, paper, plastic, and/or other generally stiff and/orfoldable materials. The materials may be treated with wax, polymers,waterproof substances, oilproof substances, etc., as known in the art.

The batteries 20 may include any type of battery. For example, thebatteries 20 may include any of a variety of different chemistries andconfigurations including, but not limited to, lithium, lithium ion(e.g., lithium iron phosphate, lithium cobalt oxide, other lithium metaloxides, etc.), lithium ion polymer, nickel metal hydride, nickelcadmium, nickel hydrogen, nickel zinc, silver zinc, alkaline, or otherbattery type/configuration. Further, the batteries 20 may include anycombination of batteries of the variety of different chemistries.

Any number of batteries 20 may be stored in the container 10, forexample, depending on the size of the container 10. In the exampleembodiment shown in FIGS. 1-4, multiple batteries 20 are stored in thecontainer 10. Alternatively, any number of batteries 20 ranging from 1to over 1,000 may be stored in the container 10. Also, when thecontainer 10 stores multiple batteries 20, the batteries 20 may bestored adjacent to each other and contacting each other, as shown inFIGS. 1-4, Alternatively, one or more spacers 13 (FIGS. 8 and 9) may beprovided to space the batteries 20 from each other and/or the side was12. The batteries 20 may be placed in various known configurations forstoring batteries 20.

Each battery 20 may include a top end 22 and a bottom end 24. Forexample, as shown in FIGS. 1-4, the top end 22 may include a positiveterminal, e.g., formed as a cylindrical protrusion (button) 26 extendingfrom a casing of the battery 20, and a vent or relief port (not shown)as known in the art. The batteries 20 may be placed inside the container10 such that the bottom ends 24 of the batteries 20 contact and rest onthe bottom surface 14 of the container 10, as shown in FIGS. 2-4. Thetop ends 22 of the batteries 20 may also be aligned with each other.

A pouch 40 may be placed on top of the batteries 20 in the container 10,and may contact and rest on the batteries 20. For example, as shown inFIGS. 1-4, the pouch 40 may be placed on top of and rest on the top ends22 of the batteries 20. The pouch 40 may be sized (e.g., length andwidth) to substantially cover the batteries 20, or to substantiallycover at least a majority of the top ends 22 of the batteries 20, In oneembodiment, the pouch 40 may have substantially the same (or slightlysmaller) length and width as the space formed by the container 10, andmay be disposed inside the container 10 with the batteries 20. Althoughthe size of the pouch 40 depends on the size of the batteries 20, thesize of the pouch 40 may range, for example, from approximately threeinches by approximately three inches to approximately two feet byapproximately two feet. Alternatively, the length and/or the width ofthe pouch 40 may be smaller or larger.

The height of the pouch 40 may depend on the contents of the pouch 40 aswill be described below. For example, the height may be approximatelyone to two inches. Alternatively, the height of the pouch 40 may besmaller or larger.

The pouch 40 may include a sealed cavity defined within a film or layer42 of material. The sealed cavity formed in the pouch 40 may contain afluid 44. For example, the pouch 40 may be a flexible container that maybe dosed or sealed (e.g., using an impulse sealer) to hold, store, orcarry the fluid 44. The layer 42 may be formed of any material used toform plastic bags or other types of flexible bags known in the art, suchas polyethylene, polystyrene, polypropylene, polyurethane, polylinedbags, polyvinyl acetate (PVA), polyvinylidene chloride (e.g., cling orplastic wrap), nylon, etc.

The layer 42 may be formed of a material having a relatively low meltingpoint. For example, the layer 42 may be capable of melting attemperatures within the range of, e.g., less than approximately 400degrees Fahrenheit, less than approximately 300 degrees Fahrenheit, lessthan approximately 200 degrees Fahrenheit, less than approximately 180degrees Fahrenheit, any range between these temperatures, etc, Also, thelayer 42 may have a thickness similar to the thickness of a layer usedto form plastic bags or other types of flexible bags known in the art,such as a thickness in the range of approximately 0.0005 inches toapproximately 0.005 inches.

The fluid 44 may include a gas (e.g., air, etc.) and/or a liquid (e.g.,water, etc.). in one example embodiment, the pouch 40 may containapproximately 100% water. In another example embodiment, the pouch 40may contain approximately 95% to approximately 98% water or otherliquid, and the remaining approximately 2% to approximately 5% mayinclude another substance. Other substances may be used to increase theviscosity, evaporation time, cooling, and/or fire extinguishing and/orfire retardant characteristics of the fluid 44. The other substances mayinclude a gel, polymer, etc. For example, sodium polyacrylate is apowder that may absorb water to form a gel that acts as a thickeningagent.

The layer 42 of the pouch 40 serves as a barrier between the fluid 44 inthe pouch 40 and the top ends 22 of the batteries 20, and may open whencontacted by contents expelled from any of the batteries 20. Forexample, FIG. 2 shows three of the batteries 20 stored in the container10 of the example embodiment with the pouch 40 located above thebatteries 20. The three batteries 20 include a first battery 30 and twobatteries 32 adjacent to the first battery 30.

The first battery 30 may undergo thermal runaway, thereby causing, amongother things, the first battery 30 to increase in temperature and/orexpel or vent contents 50 from within the first battery 30, such asflames and/or jets of fluids (e.g., gases or liquids, such as liquidelectrolyte). FIG. 3 shows the first battery 30 venting contents 50 fromwithin the first battery 30.

Due to the thermal runaway, the first battery 30 and/or the ventedcontents 50 may reach a temperature that is approximately equal to orgreater than the melting point of the material forming the layer 42 ofthe pouch 40, the temperature of the fluid 44 in the pouch 40 mayincrease sufficiently to cause the pressure inside the pouch 40 torupture the layer 42, and/or the vented contents 60 may be expelled withenough force to rupture the layer 42. Due to the melting and/or rupturedescribed above, one or more openings 46 may form in the layer 42 of thepouch 40, thereby causing the fluid 44 to leak from the pouch 40.

FIG. 4 shows the fluid 44 released from the pouch 40 through theopenings 46 formed in the layer 42. The openings 46 may be locatedgenerally above the first battery 30. As shown in FIG. 4, the openings46 may also be located generally above other batteries 32 adjacent tothe first battery 30 and/or within the container 10. Thus, the fluid 44may substantially coating and cool the first battery 30 and/or the otherbatteries, e.g., through evaporation. The fluid 44 may flow into thefirst battery 30, around the batteries 30, 32, and then evaporate. As aresult, the fluid 44 may cool the first battery 30 experiencing thermalrunaway and/or the other batteries 32 in order reduce the heat and/orcombustion occurring due to the thermal runaway of the first battery 30,and/or to assist in preventing the other batteries 32 from undergoingthermal runaway, which may lead to a chain reaction.

As noted above, in one example, the amount of fluid 44 contained in thepouch 40 depends on the size and number of batteries 20 to be placedunderneath the pouch 40, and/or the amount of fluid predicted tosufficiently cool the first battery 30 and/or the other batteries 32and/or assist in preventing a chain reaction. Similarly, the height ofthe pouch 40 may depend on the amount of fluid 44 contained in the pouch40.

Also, as noted above, in one example, the composition of the fluid 44includes substances to increase the resistance to flow of the fluid 44(e.g., a gel, a substance that forms a gel, other thickening agents,etc.). As a result, the fluid 44 may flow over the batteries 20 moreslowly, which may cool the batteries 20 more effectively, instead ofwashing past the batteries 20 relatively quickly. The fluid 44 may havealso have a low enough resistance to flow to permit the fluid 44 to flowsufficiently around the batteries 20.

FIG. 5 shows a pouch 40 a including the layer 42 and the fluid 44described above. The pouch 40 a may also be formed with sheet materialincluding air pockets 60, according to another example embodiment. Forexample, the pouch 40 a may be formed using sheet material commonlyreferred to as “bubble wrap” with the bubbles of the bubble wrap beingformed by layers 62 encapsulating the air pockets 48. The layers 62 maybe similar (e.g., in thickness and materials) to the layer 42 describedabove. The bubble wrap may be sealed at the edges of the layer 42 toform the pouch 40 a and may contain the fluid 44. Thus, the air pockets48 may be formed between the layers 42, 62. The pouch 40 a may bepositioned on the batteries 20 such that fluid 44 is separated from thebatteries 20 by a barrier formed by the layers 42, 62 and the airpockets 48. Alternatively, instead of multiple air pockets $0, the pouch40 a may be formed with a single air pocket 60 separating the fluid 44from the batteries 20.

With this configuration, when the battery experiencing thermal runaway(e.g., the first battery 30) heats, the heat from the battery istransferred to the air pockets 60 first instead of directly to the fluid44. Then, the battery experiencing thermal runaway may reach atemperature that causes the battery to expel the contents 50 and/or meltthe layers 42, 62 enough to form the opening 46 that releases the fluid44 to coat the batteries 20.

FIG. 6 shows the container 10 including a waterproof layer 16, accordingto another example embodiment. For example, the waterproof layer 16 maybe a coating, such as a plasticized coating, applied to the interiorsurfaces of the side ways 12 and/or the bottom surface 14 of thecontainer 10. Alternatively, the waterproof layer 16 may be formed as atray, such as a plastic tray having a shape that substantiallycorresponds to the shape of the interior surfaces of the side walls 12and/or the bottom surface 14 of the container 10. The plastic tray maybe inserted into the container 10 before placing the batteries 20 andthe pouch 40 in the container 10.

The waterproof layer 16 may prevent the fluid 44 released from the pouch40 from being absorbed into the container 10. When the fluid 44 isabsorbed into the container 10, the fluid 44 may not coat the batteries20 long enough to cool the batteries 20 sufficiently. Also, thewaterproof layer 16 may prevent the container 10 from being damagedand/or weakened, from leaking the fluid 44 into the surroundingenvironment, etc.

Further, in another example embodiment, the container 10 may include oneor more components 70 and one or more sensors 72 connected to the pouch40, such as the layer 42 of the pouch 40 or other portion of the pouch40 contacting the batteries 20. In the example embodiment shown in FIG.6, multiple components 70 and sensors 72 form a continuous layer affixedto a bottom surface of the layer 42 of the pouch 40. Alternatively, oneor more components 70 and one or more sensors 72 may be spaced from eachother on a bottom surface the layer 42 of the pouch 40. For example, thespacing and number of the components 70 and/or sensors 72 may depend ona size and/or number of batteries 20 to be stored below the pouch 40such that at least one component 70 and at least one sensor 72 may belocated generally near each battery 20. As another alternative, thecomponent(s) 70 and/or the sensor(s) 72 may be formed inside the pouch40, such as an upper surface of the layer 42 so that the layer 42 formsa barrier between the batteries 20 and the component(s) 70 and/or thesensor(s) 72.

The sensors 72 may detect thermal runaway. For example, the sensors 72may detect a temperature change that is above a predetermined threshold,such as 180 degrees Fahrenheit, 200 degrees Fahrenheit, 300 degreesFahrenheit, 400 degrees Fahrenheit, or another temperature threshold.Alternatively, the sensors 72 may detect a predetermined amount of asubstance expelled by a battery undergoing thermal runaway, such as agas or liquid expelled by the battery (e.g., electrolyte, carbondioxide, hydrogen gas, carbon monoxide, methane, ethane, ethylene, etc).As another alternative, the sensors 72 may detect a predetermined amountof force transmitted from the contents 50 that are vented from a batteryundergoing thermal runaway.

Upon detection of thermal runaway by the sensors 72, the components 70may cause the fluid 44 in the pouch 40 to be released. For example, thecomponents 70 may burst or make a hole or other opening in the layer 42or other portion of the pouch 40. For example, the components 70 mayinclude a valve or other device configured to open and/or close whenactuated.

FIGS. 7-9 show a container 10 a including a lid 11 according to anotherexample embodiment. FIG. 7 shows the container 10 a with the lid 11closed. FIG. 8 shows the container 10 a with the lid 11 opened, and thepouch 40 and the batteries 20 are stored inside the container 10 a. FIG.9 shows the container 10 a with the lid 11 opened, and the pouch 40removed from the container 10 a. Optionally, the batteries 20 may beplaced in a separate, more tightly fitting container 10 b inside thecontainer 10 a, Also, the spacer 13 may be provided to create a fighterfit inside the container 10 a, which may keep the batteries 20 parallel,side-by-side, and/or upright, as shown in FIG. 9.

The containers 10, 10 a described above allow one or more batteries 20to be transported and/or stored with less risk of property damage and/orbodily harm. If one of the batteries 20 undergoes thermal runaway, thebattery as well as the adjacent batteries may be cooled in order toreduce the heat and minimize the damage from the contents expelled fromthe battery undergoing thermal runaway, reduce the likelihood ofcreating a chain reaction in the other batteries, etc.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the methods and systemsdescribed above. Other embodiments will be apparent to those skilled inthe art from consideration of the specification and practice of thedisclosed methods and systems. It is intended that the specification andexamples be considered as exemplary only, with a true scope beingindicated by the following claims and their equivalents.

1-18. (canceled)
 19. A method of storing at least one object includingat least one top end and at least one bottom end, the method comprising:placing the at least one object into a container; and placing a pouchcontaining a liquid on the at least one top end of the at least oneobject such that the pouch substantially covers the top end of the atleast one object, the pouch including a layer configured to contact theat least one top end of the at least one object and formed from amaterial having a melting point of less than approximately 400 degreesFahrenheit.
 20. The method of claim 19, wherein: the at least one objectis at least one battery; and the melting point of the material is lessthan approximately 200 degrees Fahrenheit.
 21. The method of claim 19,wherein the melting point of the material is less than approximately 300degrees Fahrenheit.
 22. The method of claim 19, wherein the meltingpoint of the material is between approximately 180 degrees and 400degrees Fahrenheit.
 23. A method of storing a plurality of objectsincluding top ends and bottom ends, the method comprising: placing theplurality of objects into a container, the plurality of objects beingparallel such that the top ends of the plurality of objects are alignedand the bottom ends of the plurality of objects contact a surface of thecontainer; and placing a pouch containing a liquid on the top ends ofthe plurality of objects such that the pouch substantially covers theplurality of objects, the pouch being configured to contact the top endsof the plurality of objects and to open when contacted by contentsexpelled from at least one of the plurality of objects due to thermalrunaway.
 24. The method of claim 23, wherein: the plurality of objectsis a plurality of batteries; and the pouch includes an amount of liquidsufficient to substantially coat an outer surface of at least one of theplurality of batteries when the pouch is opened.
 25. A containerdefining a cavity and configured to transport objects, the containercomprising: a fluid; and at least one sealed enclosure configured to (i)contain the fluid, (ii) substantially cover a top end of at least oneobject in the container, (iii) make contact with the top end of the atleast one object, and (iv) release the fluid when a content from the atleast one object is expelled.
 26. The container of claim 25, wherein thesealed enclosure is a pouch.
 27. The container of claim 26, wherein: theat least one object is at least one battery; and the sealed enclosure isfurther configured to release the fluid when the content from the atleast one battery is expelled due to thermal runaway.
 28. The containerof claim 25, wherein the sealed enclosure is a plastic bag.
 29. Thecontainer of claim 28, wherein: the at least one object is at least onebattery; and the sealed enclosure is further configured to release thefluid when the content from the at least one battery is expelled due tothermal runaway.
 30. The container of claim 25, wherein: the at leastone object is at least one battery; and the sealed enclosure is furtherconfigured to release the fluid when the content from the at least onebattery is expelled due to thermal runaway.